Alignment and retention system for laterally slideably engageable mating components

ABSTRACT

An elastically averaged alignment system includes a first component having first and second alignment features, and a second component having third and fourth elastically deformable alignment elements. The first and second components are laterally slidably engageable with each other. The third elastically deformable alignment element is configured and disposed to interferingly, deformably and matingly engage with the first alignment feature. The fourth elastically deformable alignment element is configured and disposed to interferingly, deformably and matingly engage with the second alignment feature. Portions of the third and fourth elastically deformable alignment elements when engaged with respective ones of the first and second alignment features elastically deform to an elastically averaged final configuration that aligns the first component relative to the second component in six orthogonal directions by averaging the elastic deformation of the respective elastically deformable alignment elements.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application Ser.No. 61/974,107, filed Apr. 2, 2014, which is incorporated herein byreference in its entirety.

FIELD OF THE INVENTION

The subject invention relates to the art of alignment systems, moreparticularly to an elastically averaged alignment system, and even moreparticularly to an elastically averaged alignment system providingsix-way alignment of laterally slideably engageable mating components onwhich the alignment system is incorporated.

BACKGROUND

Currently, components, particularly vehicular components such as thosefound in automotive vehicles, which are to be mated together in amanufacturing process are mutually located with respect to each other byalignment features that are oversized and/or undersized to providespacing to freely move the components relative to one another to alignthem without creating an interference therebetween that would hinder themanufacturing process. One example includes two-way and/or four-way malealignment features, typically upstanding bosses, which are received intocorresponding female alignment features, typically apertures in the formof holes or slots. There is a clearance between the male alignmentfeatures and their respective female alignment features which ispredetermined to match anticipated size and positional variationtolerances of the male and female alignment features as a result ofmanufacturing (or fabrication) variances. As a result, significantpositional variation can occur between the mated first and secondcomponents having the aforementioned alignment features, which maycontribute to the presence of undesirably large variation in theiralignment, particularly with regard to the gaps and spacing betweenthem. In the case where these misaligned components are also part ofanother assembly, such misalignments can also affect the function and/oraesthetic appearance of the entire assembly. Regardless of whether suchmisalignment is limited to two components or an entire assembly, it cannegatively affect function and result in a perception of poor quality.

Accordingly, the art of alignment systems can be enhanced by providingan alignment and retention system or mechanism that can ensure precisetwo-way, four-way or six-way alignment and fastening of two componentsvia elastic averaging of a plurality elastically deformable alignmentand retention elements disposed in mating engagement with a plurality ofcorresponding alignment features.

SUMMARY OF THE INVENTION

In one exemplary embodiment of the invention, an elastically averagedalignment system includes a first component and a second component. Thefirst component includes at least one of a first alignment featurefixedly disposed with respect to the first component, and at least oneof a second alignment feature fixedly disposed with respect to the firstcomponent. The second component includes at least one of a thirdelastically deformable alignment element fixedly disposed with respectto the second component, and at least one of a fourth elasticallydeformable alignment element fixedly disposed with respect to the secondcomponent. The first and second components are laterally slidablyengageable with each other. A respective one of the third elasticallydeformable alignment element is configured and disposed tointerferingly, deformably and matingly engage with a respective one ofthe first alignment feature. A respective one of the fourth elasticallydeformable alignment element is configured and disposed tointerferingly, deformably and matingly engage with a respective one ofthe second alignment feature. Portions of the third and fourthelastically deformable alignment elements when engaged with respectiveones of the first and second alignment features elastically deform to anelastically averaged final configuration that aligns the first componentrelative to the second component in six planar orthogonal directions byaveraging the elastic deformation of the respective elasticallydeformable alignment elements.

The above features and advantages and other features and advantages ofthe invention are readily apparent from the following detaileddescription of the invention when taken in connection with theaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Other features, advantages and details appear, by way of example only,in the following detailed description of embodiments, the detaileddescription referring to the drawings in which:

FIG. 1 depicts an assembly of a first component aligned and retainedrelative to a second component via an elastically averaged alignment andretention system, in accordance with an embodiment of the invention;

FIG. 2 depicts an isometric view of the first component of FIG. 1 with amating side of the first component visible, in accordance with anembodiment of the invention;

FIG. 3 depicts an isometric view of the second component of FIG. 1 witha mating side of the second component visible, in accordance with anembodiment of the invention;

FIG. 4 depicts an expanded isometric view of an alignment feature of thefirst component, in accordance with an embodiment of the invention;

FIG. 5 depicts an expanded isometric view of an elastically deformablealignment element of the second component, in accordance with anembodiment of the invention;

FIG. 6 depicts a side view of the elastically deformable alignmentelement of FIG. 5 elastically, deformably and matingly engaged with thealignment feature of FIG. 4, where the engagement surfaces are depictedoverlapping to illustrate an interference fit therebetween, inaccordance with an embodiment of the invention;

FIG. 7A depicts a cross section view through a portion of the assemblyof FIG. 1, in accordance with an embodiment of the invention;

FIG. 7B depicts an expanded portion of the cross section view of FIG.7A, in accordance with an embodiment of the invention; and

FIG. 8 depicts a cross section view through another portion of theassembly of FIG. 1, in accordance with an embodiment of the invention.

DESCRIPTION OF THE EMBODIMENTS

The following description is merely exemplary in nature and is notintended to limit the present disclosure, its application or uses. Forexample, the embodiments shown comprise vehicle components but thealignment system may be used with any suitable components to provideelastic averaging for precision location and alignment of all manner ofmating components and component applications, including many industrial,consumer product (e.g., consumer electronics, various appliances and thelike), transportation, energy and aerospace applications, andparticularly including many other types of vehicular components andapplications, such as various interior, exterior and under hoodvehicular components and applications. It should be understood thatthroughout the drawings, corresponding reference numerals indicate likeor corresponding parts and features.

As used herein, the term “elastically deformable” refers to components,or portions of components, including component features, comprisingmaterials having a generally elastic deformation characteristic, whereinthe material is configured to undergo a resiliently reversible change inits shape, size, or both, in response to application of a force. Theforce causing the resiliently reversible or elastic deformation of thematerial may include a tensile, compressive, shear, bending or torsionalforce, or various combinations of these forces. The elasticallydeformable materials may exhibit linear elastic deformation, for examplethat described according to Hooke's law, or non-linear elasticdeformation.

Elastic averaging provides elastic deformation of the interface(s)between mated components, wherein the average deformation provides aprecise alignment, the manufacturing positional variance being minimizedto X_(min), defined by X_(min)=X/√N, wherein X is the manufacturingpositional variance of the locating features of the mated components andN is the number of features inserted. To obtain elastic averaging, anelastically deformable component is configured to have at least onefeature and its contact surface(s) that is over-constrained and providesan interference fit with a mating feature of another component and itscontact surface(s). The over-constrained condition and interference fitresiliently reversibly (elastically) deforms at least one of the atleast one feature or the mating feature, or both features. Theresiliently reversible nature of these features of the components allowsrepeatable insertion and withdrawal of the components that facilitatestheir assembly and disassembly. In some embodiments, the elasticallydeformable component configured to have the at least one feature andassociated mating feature disclosed herein may require more than one ofsuch features, depending on the requirements of a particular embodiment.Positional variance of the components may result in varying forces beingapplied over regions of the contact surfaces that are over-constrainedand engaged during insertion of the component in an interferencecondition. It is to be appreciated that a single inserted component maybe elastically averaged with respect to a length of the perimeter of thecomponent. The principles of elastic averaging are described in detailin commonly owned, co-pending U.S. patent application Ser. No.13/187,675, now U.S. Pat. No. 8,695,201, the disclosure of which isincorporated by reference herein in its entirety. The embodimentsdisclosed above provide the ability to convert an existing componentthat is not compatible with the above-described elastic averagingprinciples, or that would be further aided with the inclusion of anelastically averaged alignment and retention system as herein disclosed,to an assembly that does facilitate elastic averaging and the benefitsassociated therewith.

Any suitable elastically deformable material may be used for the matingcomponents and alignment features disclosed herein and discussed furtherbelow, particularly those materials that are elastically deformable whenformed into the features described herein. This includes various metals,polymers, ceramics, inorganic materials or glasses, or composites of anyof the aforementioned materials, or any other combinations thereofsuitable for a purpose disclosed herein. Many composite materials areenvisioned, including various filled polymers, including glass, ceramic,metal and inorganic material filled polymers, particularly glass, metal,ceramic, inorganic or carbon fiber filled polymers. Any suitable fillermorphology may be employed, including all shapes and sizes ofparticulates or fibers. More particularly any suitable type of fiber maybe used, including continuous and discontinuous fibers, woven andunwoven cloths, felts or tows, or a combination thereof. Any suitablemetal may be used, including various grades and alloys of steel, castiron, aluminum, magnesium or titanium, or composites thereof, or anyother combinations thereof. Polymers may include both thermoplasticpolymers or thermoset polymers, or composites thereof, or any othercombinations thereof, including a wide variety of co-polymers andpolymer blends. In one embodiment, a preferred plastic material is onehaving elastic properties so as to deform elastically without fracture,as for example, a material comprising an acrylonitrile butadiene styrene(ABS) polymer, and more particularly a polycarbonate ABS polymer blend(PC/ABS). The material may be in any form and formed or manufactured byany suitable process, including stamped or formed metal, composite orother sheets, forgings, extruded parts, pressed parts, castings, ormolded parts and the like, to include the deformable features describedherein. The elastically deformable alignment features and associatedcomponent may be formed in any suitable manner. For example, theelastically deformable alignment features and the associated componentmay be integrally formed, or they may be formed entirely separately andsubsequently attached together. When integrally formed, they may beformed as a single part from a plastic injection molding machine, forexample. When formed separately, they may be formed from differentmaterials to provide a predetermined elastic response characteristic,for example. The material, or materials, may be selected to provide apredetermined elastic response characteristic of any or all of theelastically deformable alignment features, the associated component, orthe mating component. The predetermined elastic response characteristicmay include, for example, a predetermined elastic modulus.

As used herein, the term vehicle is not limited to just an automobile,truck, van or sport utility vehicle, but includes any self-propelled,towed, or movable conveyance suitable for transporting or supporting aburden.

In accordance with an example embodiment of the invention, and withreference to FIGS. 1-3, an elastically averaged alignment system 10includes a first component 100 having at least one of a first alignmentfeature 102 (individually herein referred to by reference numerals102.1, 102.2 . . . ) fixedly disposed with respect to the firstcomponent 100, or at least one of a second alignment feature 104(individually herein referred to by reference numerals 104.1, 104.2 . .. ) fixedly disposed with respect to the first component 100, and asecond component 200 having at least one of a third elasticallydeformable alignment element 202 (individually herein referred to byreference numerals 202.1, 202.2 . . . ) fixedly disposed with respect tothe second component 200, and at least one of a fourth elasticallydeformable alignment element 204 (individually herein referred to byreference numerals 204.1, 204.2 . . . ) fixedly disposed with respect tothe second component 200. The first and second components 100, 200 arelaterally slideably engageable with each other in a manner that will bedescribed in more detail below.

With reference to FIGS. 4-7B (FIG. 4 depicts an expanded view of detail150 of FIG. 2, FIG. 5 depicts an expanded view of detail 250 of FIG. 3,and FIG. 7B depicts an expanded view of detail 300 of FIG. 7A) incombination with FIGS. 1-3, respective ones of the third elasticallydeformable alignment element 202 are configured and disposed tointerferingly, deformably and matingly engage with associated respectiveones of the first alignment feature 102, and respective ones of thefourth elastically deformable alignment element 204 is configured anddisposed to interferingly, deformably and matingly engage with arespective one of the second alignment feature 104. Portions of thethird and fourth elastically deformable alignment elements 202, 204 whenengaged with respective ones of the first and second alignment features102, 104 elastically deform to an elastically averaged finalconfiguration that aligns the first component 100 relative to the secondcomponent 200 in six planar orthogonal directions, such as the+/−x-direction, the +/−y-direction, and the +/−z-direction of anorthogonal coordinate system (see FIG. 1), for example, which is hereinreferred to as six-way alignment, by averaging the elastic deformationof the respective elastically deformable alignment elements 202, 204.

As depicted in FIGS. 2 and 3, the elastically averaged alignment system10 includes an arrangement wherein the first component 100 has more thanone of the first and second alignment features 102, 104, and the secondcomponent 200 has more than one of the third and fourth elasticallydeformable alignment elements 202, 204. The more than one of the thirdand fourth elastically deformable alignment elements 202, 204 aregeometrically distributed with respect to respective ones of the morethan one first and second alignment features 102, 104, such thatportions of the elastically deformable alignment elements of respectiveones of the more than one third and fourth elastically deformablealignment elements 202, 204, when engaged with respective ones of themore than one first and second alignment features 102, 104, elasticallydeform to an elastically averaged final configuration that furtheraligns the first component 100 relative to the second component 200 insix planar orthogonal directions.

As depicted in FIGS. 2 and 4, the first alignment feature 102 is formedby a projection 106 having a curved cross section that extends off of afirst wall 108. In an embodiment, the curved cross section has a waveshape. As depicted in FIG. 2, the first wall 108 is on one side of alinear pocket 110 (individually herein referred to by reference numerals110.1, 110.2 . . . ) formed in the first component 100, and a secondwall 112 opposing the first wall 108 is on an opposite side of thelinear pocket 110. The first alignment feature 102 is disposed extendingsideways off of the first wall 108, and the second alignment feature 104forms a portion of the second wall 112.

As depicted in FIGS. 3, 5, 7A and 7B, the third elastically deformablealignment element 202 is formed by a curved projection 206 having acurved cross section that extends sideways off of a first side 208 of athird wall 210 (individually herein referred to by reference numerals210.1, 210.2 . . . ). In an embodiment, the curved cross section has acrescent shape.

As also depicted in FIGS. 3, 5, 7A and 7B, the fourth elasticallydeformable alignment element 204 is formed by a distal projection 212that extends sideways off of a second side 214 of the third wall 210 ata distal end 216 of the third wall 210. The second side 214 of the thirdwall 210 faces away from the first side 208 of the third wall 210. In anembodiment, the third wall 210 has slots 218 on each side of the distalprojection 212, where the slots 218 are open at and extend from thedistal end 216 of the third wall 210 toward a proximal end 220 of thethird wall 210. The portion of the third wall 210 between the slots 218and having the distal projection 212 forms a cantilevered section of thethird wall 210 that is capable of undergoing elastic deflection in amanner similar to how a cantilevered beam may be deflected at its freeend.

In an embodiment, the first and second components 100, 200 are assembledtogether to arrive at the assembly depicted in FIG. 1 as follows. First,the mating side 224 of the second component 200 (mating side depicted inFIG. 3) is oriented proximate to and in face-to-face relationship withthe mating side 116 of the first component (mating side depicted in FIG.2), but laterally offset such that an inner end 222 (see FIG. 7A) of thethird wall 210 of the second component 200 is poised for entry into theopen end 114 (see FIG. 2) of the linear pocket 110 of the firstcomponent 100. Then, the second component 200 is laterally and slideablyengaged with the first component 100 such that the third and fourthelastically deformable alignment elements 202, 204 fully engage withrespective ones of the first and second alignment features 102, 104, asdepicted in FIGS. 6, 7A and 7B. A ramped surface 226 (see FIG. 7B) onthe distal projection 212, along with the curvatures of the firstalignment feature 102 and third elastically deformable alignment element202, facilitates the assembly of the first and second components 100,200. As depicted in FIGS. 6 and 7B, the first alignment feature 102 andthe third elastically deformable alignment element 202 are disposed inan interference fit condition 302 in a first z-direction, and the secondalignment feature 104 and the fourth elastically deformable alignmentelement 204 are disposed in an interference fit condition 304 in asecond y-direction orthogonal to the first z-direction, when the firstand second components 100, 200 are fully engaged with each other,thereby elastically aligning and restraining the first and secondcomponents 100, 200 in the +/−y and +/−z directions. While theengagement surfaces depicted in FIGS. 6, 7A and 7B are depictedoverlapping each other to illustrate interference fit conditions 302,304 (dotted lines depicting the degree of overlap), it will beappreciated that this is for illustration purposes only so as toillustrate an interference fit between the respective parts, and that inactuality the elastically deformable alignment elements 202, 204 willelastically deform by the amount of the interference fit conditionshown. For example, the cantilevered crescent shaped end of the thirdelastically deformable alignment element 202 will tend to flatten outslightly and bend slightly at the cantilevered free end by the amount ofthe interference fit condition 302, and the cantilevered distalprojection 212 of the fourth elastically deformable alignment element204 will tend to bend slightly at the cantilevered free end by theamount of the interference fit condition 304. Elastic alignment andrestraint of the first and second components 100, 200 in the+/−x-directions is achieved by the crescent shaped third elasticallydeformable alignment element 202 being elastically deformably nestled ina trough of the wave shaped first alignment feature 102.

With reference now to FIG. 8, it can be seen that the first and secondcomponents 100, 200 are tightly fit relative to each other by the thirdelastically deformable alignment element 202 of the second component 200being interferingly captured under the first alignment feature 102 ofthe first component 100, which pulls the mating side 224 of the secondcomponent 200 snugly against the first wall 108, and therefore snuglyagainst the mating side 116, of the first component 100, with little orno gap therebetween. As depicted in FIG. 8, only an end portion of thecrescent shaped cantilevered projection of the third elasticallydeformable alignment element 202 overlaps the wave shaped projection ofthe first alignment feature 102, which provides for cantilevered elasticdeflection of the third elastically deformable alignment element 202when engaged with the first alignment feature 102.

With reference now back to FIGS. 2 and 3, an embodiment includes anarrangement where there are two sets of the first and second alignmentfeatures 102, 104 (denoted by 102.1, 102.2, 104.1, 104.2) arranged inrespective spaced-apart linear pockets 110.1, 110.2, and two sets of thethird and fourth elastically deformable alignment elements 202, 204(denoted by 202.1, 202.2, 204.1, 204.2) arranged on respectivespaced-apart linear walls 210.1, 210.2. Like features and elements ofthe two sets are arranged so that any biasing forces they create betweenthem oppose each other. For example, when elastically, deformably andmatingly engaged with each other, the fourth elastically deformablealignment element 204.1 of the first set (toward the left in FIG. 3) iselastically deformed inward thereby creating an outward biasing force onthe second alignment feature 104.1 of the first set (toward the left inFIG. 2), and the fourth elastically deformable alignment element 204.2of the second set (toward the right in FIG. 3) is elastically deformedinward thereby creating an outward biasing force on the second alignmentfeature 104.2 of the second set (toward the right in FIG. 2), resultingin two outward biasing forces that oppose each other. The same resultwould be achieved if the placement of the first and second alignmentfeatures of the first and second sets, and the corresponding first andsecond elastically deformable alignment elements of the first and secondsets, were switched. As such, the scope of the invention is not limitedto only the orientation of features and elements depicted in FIGS. 2 and3.

In view of all that is disclosed, illustrated, described, andincorporated by reference herein, it will be appreciated that the scopeof the invention is not limited to only the use of the herein disclosedelastically deformable alignment elements and the correspondingalignment features, but also encompasses the use of such elements andfeatures in combination with other elastic averaging alignment features,male or female.

When the first component 100 and second component 200 are components ofa vehicle, an advantageous assembly results because the clamping force,together with the elastic deformation of the alignment features that hasthese parts in pressing contact already, reduces the tendency of thecomponents to vibrate or rattle against one another, and thus improvesthe noise, vibration and harshness (NVH) characteristics of thecomponents and the vehicle in which they are installed. The selectiveengagement of the elastically deformable alignment elements and thecorresponding alignment features also provides a stiffened assembly ofthe first component 100 and second component 200 when the first andsecond components are mutually mated to each other, including astiffness that is greater than that realized by using the alignmentfeatures alone, since the clamping force between the first component andsecond component increases the stiffness of the assembly, for example.In an embodiment, the first component 100 is a hinge portion of a fueldoor for a vehicle, and the second component 200 is a cover portion ofthe fuel door.

While the invention has been described with reference to exemplaryembodiments, it will be understood by those skilled in the art thatvarious changes may be made and equivalents may be substituted forelements thereof without departing from the scope of the invention. Inaddition, many modifications may be made to adapt a particular situationor material to the teachings of the invention without departing from theessential scope thereof. Therefore, it is intended that the inventionnot be limited to the particular embodiments disclosed, but that theinvention will include all embodiments falling within the scope of theapplication.

What is claimed is:
 1. An elastically averaged alignment system,comprising: a first component comprising at least one first alignmentfeature fixedly disposed with respect to the first component, and atleast one second alignment feature fixedly disposed with respect to thefirst component; a second component comprising at least one firstelastically deformable alignment element fixedly disposed with respectto the second component, and at least one second elastically deformablealignment element fixedly disposed with respect to the second component;wherein the first and second components are laterally slidablyengageable with each other; wherein the first elastically deformablealignment element is configured and disposed to interferingly,deformably and matingly engage with the first alignment feature; whereinthe second elastically deformable alignment element is configured anddisposed to interferingly, deformably and matingly engage with thesecond alignment feature; wherein portions of the first and secondelastically deformable alignment elements when engaged with respectiveones of the first and second alignment features elastically deform to anelastically averaged final configuration that aligns the first componentrelative to the second component in six orthogonal directions byaveraging the elastic deformation of the portions of the first andsecond elastically deformable alignment elements; wherein the firstelastically deformable alignment element comprises a curved projectionhaving a curved cross section that extends from of a first side of athird wall; and wherein the second elastically deformable alignmentelement comprises a distal projection that extends from a second side ofthe third wall at a distal end of the third wall, the second side of thethird wall facing away from the first side of the third wall.
 2. Theelastically averaged alignment system of claim 1, wherein the firstalignment feature comprises a projection having a curved cross sectionthat extends from a first wall.
 3. The elastically averaged alignmentsystem of claim 2, wherein the curved cross section of the firstalignment feature is sinusoidal shaped.
 4. The elastically averagedalignment system of claim 1, wherein: the first component comprises apocket having opposing first and second side walls; the first alignmentfeature is disposed on the first side wall; and the second alignmentfeature is a portion of the second side wall.
 5. The elasticallyaveraged alignment system of claim 1, wherein the curved cross sectionis a crescent shaped.
 6. The elastically averaged alignment system ofclaim 1, wherein: the third wall comprises slots, the slots formingcantilevered sections of the third wall, the distal projection extendsfrom one of said cantilevered sections.
 7. The elastically averagedalignment system of claim 1, wherein: the first alignment feature andthe first elastically deformable alignment element extend in a firstdirection; and the second alignment feature and the second elasticallydeformable alignment element extend in a second direction orthogonal tothe first direction.
 8. The elastically averaged alignment system ofclaim 1, wherein: the first component comprises a first mating side; thesecond component comprises a second mating side; and the firstelastically deformable alignment element when interferingly, deformablyand matingly engaging with the first alignment feature biases the firstand second mating sides toward each other.
 9. The elastically averagedalignment system of claim 1, wherein: the first component is a hingeportion; and the second component is a cover portion.
 10. Theelastically averaged alignment system of claim 1, wherein: the firstcomponent comprises a first portion of a fuel door; and the secondcomponent comprises a second portion of the fuel door.